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e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 6 Ver. II (Nov. - Dec. 2015), PP 21-29
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Abstract : Gas metal arc welding is process is becoming widespread in the welding industries as it can easily
be applied to variety of metals. Quality of weldment depends upon welding input parameters. This experimental
study aims at developing a multi-objective optimization problem to achieve desired weld bead geometry of
GMAW. Objective functions optimized by Taguchis L9 orthogonal array design and S/N ratio. Welding
voltage, welding speed, wire feed rate and gas flow rate have been selected as the input process parameters.
Quality targets are bead width, bead height and depth of penetration for AISI 446. The Grey relational analysis
in combination with Taguchi approach is used to solve this multi-objective optimization problem. Additionally
the most significant factor identified by using ANOVA.
Keywords -Bead Geometry, Gas Metal Arc Welding, Grey Relational Analysis,Taguchi Orthogonal Array
I.
Introduction
The Gas metal arc welding processes are quickly replacing the shield arc stick electrode process
because the GMAW process can easily be applied to both ferrous and nonferrous metals. GMAW processes are
also popular as they can deposit a large quantity of weld metal in a relatively short period of time. GMAW plays
a significant role in many industries. Welding is mainly important in heavy fabrication industry, which includes
machinery, farming equipment, process tools for manufacturing and mining, and infrastructure for petroleum
refining and distribution. During the welding process, input parameters influenced the weldment quality.
Therefore, welding becomes as a multi-input multi-output process. To catch the preferred weld quality in
GMAW process it is necessary to study input and output process parameters interrelationships. The optimization
and prediction of process parameters is a significant aspect in welding process. This experimental study aims at
developing a multi-objective optimization problem to achieve preferred weld bead geometry for AISI 446 grade
of steel of 8 mm thickness in GMAW process by using grey-based Taguchi method. It is necessary to control
shape of weld bead geometry in determining mechanical properties as it is affected by weld bead geometry
shape. Therefore, proper selection of process parameter is necessary. It is not easy task to developed
mathematical models which gives relationship between input and output process parameters of GMAW process
because there were some unknown nonlinear process parameters [1]. Therefore, it is better to solve this problem
by experimental models. Multiple regression technique was used to found the empirical models for various
welding processes [2, 3]. Datta et at [4] planned multiple regression model and predicted the bead geometry
volume of SAW process. Gunaraj et al [5-6] used five-level factorial techniques to developed mathematical
models for prediction and optimization of weld bead for the SAW process. Kim et al [7] used multiple
regression and neural network to develop an intelligent system for GMAW process. Li et al [8] used SelfAdaptive Offset Network to know the non-linear relationship between the geometry variables and process
parameters of SAW process. Tang et al [9] examined the correlation between process parameters and bead
geometry for TIG welding process using a back propagation neural network. Thao et al [10] using SPSS
window software developed correlation between process parameters and bead geometry parameters for GTAW
process.
.
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
called signal-to-noise ratio to evaluate optimal parameters settings. The S/N ratio takes both the mean and the
variability into account which is the ratio of the mean to the standard deviation. The quality characteristic of the
process to be optimized defines the ratio. The standard S/N ratio has three criterias, Lower the best (LB),
Nominal is best (NB) and higher the better ((HB). The parameter combination, which has the highest S/N ratio,
gives the optimal setting.
In Grey relational analysis, Grey relational generation is the process which normalizes the experimental
data range from zero to one and it transferring the original data into comparability Sequences. Next, Grey
relational coefficient is calculated based on normalized experimental data to represent the relationship between
the actual and desired experimental data. Overall Grey relational grade be an average of the Grey relational
coefficient of selected responses. Grey relational grade gives the overall performance characteristics of the
multiple response process. This method converts a multiple objective problem into single objective with the
objective function as overall Grey relational grade.
max ()
(1)
max min ()
Bead penetration should follow larger-the-better criterion, which can be stated as:
Xi(k) =
()min ()
(2)
max ()min ()
Where, xi(k) = the value after the Grey relational generation, min yi(k) = the smallest value of yi(k) for the kth
response, and max yi(k) = the largest value of yi(k) for the kth response. The normalized data after Grey relational
generation are tabularized in table 5. An ideal sequence is x0(k) (k=1, 2, 3......,25) for the responses. Grey
relational grade is to reveal the degree of relation between the 9 sequences [x0(k) and xi(k), i=1, 2, 3........9]
(Table 3).
We can calculate the Grey relational coefficient i(k) as:
i (k)=
min +max
()+max
(3)
where, 0i = x0(k) xi(k) = difference of the absolute value x 0(k) and xi(k),
is the distinguishing coefficient 0 1
min = jminikminx0(k) xj(k)= the smallest value of 0i, and
max= jminikmaxx0(k) xj(k)= largest value of 0i.
The Grey relational grade i can be computed after be an average of the Grey relational coefficients as:
i=
()
DOI: 10.9790/1684-12622129
(4)
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
where n = number of process responses. The greater value of Grey relational grade relates to extreme
relational degree between the reference sequence x0(k) and the known sequence xi(k). The reference sequence
x0(k) represents the best process sequence; therefore, higher Grey relational grade means that the corresponding
parameter combination is nearer to the optimal. The mean response of the Grey relational grade, its grand mean
and the main effect plot are very significant as optimal process condition may well be evaluated from this plot.
DOI: 10.9790/1684-12622129
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
Table 1 Process parameters and their limits
Process Parameters
Open Circuit Voltage
Gas Flow Rate
Wire Feed Rate
Welding Speed
Notation
V
G
F
S
Levels of Factors
1
2
26
27
16
17
1.75
2.0
20
22
Unit
Volts
lit/min
cm/min
cm/min
3
28
18
2.25
24
Voltage
(V)
Welding Speed
(cm/min)
C
0.08
0.02
Si
0.35
0.42
Mn
0.85
1.80
S
0.003
0.01
P
0.030
0.02
Cr
23.45
24.80
Ni
0.40
12.92
Mo
.
0.01
Ti
0.124
0.049
Cu
0.03
Nu
0.025
Fe
74.84
59.772
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
conducted using GMAW machine based on Taguchis orthogonal array design matrix which consist of nine
trails.
Bead Width
(mm)
8.14
Bead Height
(mm)
1.44
8.56
2.29
7.66
10.69
3.39
6.42
10.26
3.58
5.94
8.46
2.53
6.27
8.29
3.22
7.06
8.58
2.68
6.48
10.91
2.88
6.42
10.17
3.63
7.43
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
Table 5 Data preprocessing of all performance characteristic (Grey relational generation)
Experiment No.
Bead Width
(mm)
Bead Height
(mm)
Penetration
(mm)
Ideal Sequence
0.8394
0.9087
0.5000
0.7121
0.5560
0.8776
0.0667
0.0996
0.2449
0.1970
0.0207
0.0000
0.7424
0.4564
0.1684
0.7939
0.1701
0.5714
0.7061
0.3942
0.2755
0.0000
0.3112
0.2449
0.2242
0.0000
0.7602
The 0i for each of the responses have been calculated and tabulated in Table 6. These evaluations of 0i for
each response have been collected to evaluate Grey relational coefficient.
Table 6Evaluation of 0i for each of the responses
Experiment
No.
Ideal Sequence
Bead Width
(mm)
1
Bead Height
(mm)
1
Penetration
(mm)
1
0.1606
0.0913
0.5000
0.2879
0.4440
0.1224
0.9333
0.9004
0.7551
0.8030
0.9793
1.0000
0.2576
0.5436
0.8316
0.2061
0.8299
0.4286
0.2939
0.6058
0.7245
1.0000
0.6888
0.7551
0.7758
1.0000
0.2398
In Table 6, reference sequence is ideal sequence. After calculating max, min and 0i, altogether grey
relational coefficients may be evaluated by (3). These Grey relational coefficients for each response have been
collected to calculate Grey relational grade and are exposed in Table 7.
Table 7Grey relational coefficient of each performance characteristics (with = 0.5)
Experiment No.
Bead Width
(mm)
Bead Height
(mm)
Penetration
(mm)
Ideal Sequence
0.7569
0.8456
0.5000
0.6346
0.5297
0.8033
0.3488
0.3570
0.3984
0.3837
0.3380
0.3333
0.6600
0.4791
0.3755
0.7082
0.3760
0.5385
0.6298
0.4522
0.4083
0.3333
0.4206
0.3984
0.3919
0.3333
0.6759
Grey relational grade is the total characteristic of all the features of weld quality. The overall Grey relational
grade has been determined by (4) and is tabulated in Table 8.
DOI: 10.9790/1684-12622129
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
Table 8 Grey relational grade
Experiment No.
0.8458
0.7768
0.3737
0.3557
0.5652
0.6241
0.5498
0.3916
0.5093
Thus, the multi-objective optimization problem can be transformed into a single comparable objective function
optimization problem by the combination of Taguchi approach and Grey relational analysis. Maximum grey
relational grade equivalents factor combination to the closer optimal parametric setting.
The mean response for the overall Grey relational grade is shown in Table 9.
Table 9Response table (mean) for Overall Grey relational grade
Grey relational grade
Factors
Level 1
Level 2
Level 3
MAX
MIN
Delta
0.6687
0.5300
0.4905
0.6687
0.4905
0.1782
0.5825
0.5941
0.5125
0.5941
0.5125
0.0816
0.6196
0.5602
0.5094
0.6196
0.5094
0.1102
0.6363
0.6763
0.3766
0.6763
0.3766
0.2997
DOI: 10.9790/1684-12622129
Level 1
-3.4953
-4.6935
-4.1581
-3.9264
Level 2
-5.5146
-4.5223
-5.0324
-3.3974
Level 3
-6.1872
-5.8056
-5.8591
-8.4824
MEAN
-5.0657
-5.0071
-5.0166
-5.2688
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
M a in E ffe c t s P lo t fo r S N ra t io s
D ata M ean s
-4
-5
-6
-7
-8
M e a n o f S N r a ti o s
26
27
28
1 .7 5
2 .0
2 .2 5
-4
-5
-6
-7
-8
20
22
24
16
17
18
L e ve l s o f F a c t o r s
S ig n a l-t o -n o is e : L a rg e r is b e t t e r
=m +
0
=1 (i- m)
(7)
That means the predicted Grey relational grade is equivalent to the mean Grey relational grade plus the
summation of the difference between overall mean Grey relational grade and mean Grey relational grade for
each of the factors at optimal level.
S/N ratio for predictable grey relational grade have been calculated using (6)
S/N ratio for predictable grey relational grade = -1.3313
The Grey relational grade and S/N ratio for Initial factor settings V1 F1 S1 G1, predicted optimal
parametric process setting V1 F1 S1 G2 and experimental optimal parametric process setting V1 F1 S1 G2 are
shown in column no. 2, 3 and 4 respectively in Table 11.
Table 11 signifies the comparison of the predicted bead geometry parameters with that of actual by
using the optimal welding conditions; improvement in overall Grey relational grade has been observed. This
confirms the usefulness of the proposed approach in relation to process optimization, where more than one
objective has to be fulfilled concurrently.The overall Grey relational grade is main performance feature in Greybased Taguchi method; The Grey relational grade is the demonstrative of all individual performance
characteristics. In the current study, objective functions selected are relative to parameters of bead geometry;
and all the responses give equal weight age. It may be noted that results of a confirmatory experiment shows
that using optimal parameter setting the weldment undertakes lower value of depth of penetration. The Taguchi
optimization technique and the optimal parametric combination thus calculated depend on the selected response
variables and their individual weight ages.
Table 11 Results of confirmatory experiment
Initial factor setting
Levels of factors
Bead Width
Bead Height
Penetration
S/N ratio of overall Grey relational grade
Overall Grey relational grade
Improvement in grey relational grade = 0.0158
DOI: 10.9790/1684-12622129
V1 F1 S1 G1
8.14
1.44
6.92
-1.7460
0.8179
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Process Parameter Optimization of Bead geometry for AISI 446 in GMAW Process Using Grey
3.9 Analysis of variance (ANOVA)
ANOVA is a statistical technique, which can infer some important conclusions based on analysis of the
experimental data. If the P-value for a term appears less than 0.05 then it may be concluded that, the effect of
the factor is significant on the selected response. Using MINITAB release 15, ANOVA for overall Grey
relational grade has been exposed in Table 12. It is saw that P-value for Gas flow rate is 0.040 (less than 0.05).
So it is obvious that gas flow rate is the most significant factor. The effects of other factors on Grey relational
grade look insignificant. Gas flow rate G (P-value highest) come to be the most insignificant factor.
Table 12 Analysis of variance using adjusted SS for tests
Source
V
F
S
G
Error
DF
2
2
2
2
6
SS
0.0526
0.0117
0.0182
0.1589
0.1888
Total
14
0.2414
MS
0.0263
0.0058
0.0091
0.0794
0.315
F
0.84
0.15
0.25
5.78
P
0.479
0.862
0.790
0.040
IV. Conclusion
The following conclusions are from the experimentation:
1. Grey based Taguchi method was successfully applied for process parameter optimization of bead geometry
for AISI 446 in GMAW process.
2. In order to achieve the best bead geometry viz. maximum bead penetration and minimum bead width as
well as bead height following optimal settings were determined: Welding Voltage 26 V, wire feed rate1.75 cm/min, welding speed- 20 cm/min and gas flow rate- lit/min.
3. Gas flow rate was identified as the most significant factor for bead geometry using ANOVA.
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